Rod hanger for securing a rod to a substrate

ABSTRACT

A rod hanger for securing a rod to a substrate includes a mounting portion configured for engaging the substrate, a rod receiving portion configured for receiving the rod and a connecting element configured for vertically displacing the mounting portion and the rod receiving portion. In addition, at least one anti-rotation element configured for engaging the substrate is provided on the mounting portion.

BACKGROUND

The present invention relates to a rod hanger used to secure a rod to asubstrate, more specifically, to such rod hangers supporting a suspendedceiling, conduit, or other objects from a substrate.

It is known in the prior art to support a suspended ceiling or objectsfrom a concrete ceiling or other substrate using a plurality of bracketsattaching to a concrete ceiling (typically the underside of the floorstructure above). Generally, each bracket is associated with acorresponding rod.

Since the floor or substrate from which the brackets are attached istypically made of concrete or other hard building material, powderactuated tools are often used during the bracket installation. Thebracket typically includes a mounting portion that engages both asecuring pin and the substrate. Each bracket also typically includes athreaded portion for engaging the rod. The mounting portion and thethreaded portion are connected to each other.

One disadvantage of the prior art brackets is that they often becomemisaligned after installation. More specifically, a moment or twistingforce placed on the rod hanger when attaching the rod to the bracketcauses the bracket to rotate from its desired orientation. Such rotationmay generally cause a misalignment and/or support malfunction of thethreaded rod. As a result of the brackets becoming misaligned, theinstaller will have to readjust the rod hanger to its original position.

Thus, there is a need for an improved rod hanger or hanger bracket whichcan resist the above-identified rotational forces. There is also a needfor such an improved bracket which is securely attachable upon concreteceilings or other substrates.

SUMMARY

To address the above-identified needs, and to alleviate the need forreadjusting brackets which have rotated from their original positionsafter installation, the invention provides a rod hanger withanti-rotation elements for reducing the effect of rotational momentsencountered during or after installation.

More specifically, the present rod hanger for securing a rod to asubstrate includes a mounting portion configured for engaging thesubstrate, a rod receiving portion configured for receiving the rod anda connecting element configured for vertically displacing the mountingportion and the rod receiving portion. In addition, the present rodhanger includes at least one anti-rotation element on the mountingportion configured for engaging the substrate.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a side view of the present rod hanger secured to a substratewith a rod attached, both the substrate and the rod shown fragmentarily;

FIG. 2 is a perspective view of the present rod hanger with a fastenercaptured within a hole on the mounting portion;

FIG. 3 is a top view of an alternate embodiment the present rod hanger;

FIG. 4 is a cross-section taken along the line 4-4 of FIG. 3 and in thedirection generally indicated;

FIG. 5 is a top view of a second alternate embodiment of the rod hangerof FIG. 1;

FIG. 6 is a cross-section taken along the line 6-6 of FIG. 5 and in thedirection generally indicated;

FIG. 7 is a top view of a third alternate embodiment of the present rodhanger;

FIG. 8 is a cross-section taken along the line 8-8 of FIG. 7 and in thedirection generally indicated;

FIG. 9 is a top view of a fourth alternate embodiment of the rod hangerof FIG. 1;

FIG. 10 is a cross-section taken along the line 10-10 of FIG. 9 and inthe direction generally indicated;

FIG. 11 is a top view of a fifth alternate embodiment of the rod hangerof FIG. 1; and

FIG. 12 is a cross-section taken along the line 12-12 of FIG. 11 and inthe direction generally indicated.

FIG. 13 is a top view of a sixth alternate embodiment of the rod hangerof FIG. 1;

FIG. 14 is a cross-section taken along the line 14-14 of FIG. 13 and inthe direction generally indicated;

FIG. 15 is a top view of a seventh alternate embodiment of the rodhanger of FIG. 1; and

FIG. 16 is a cross-section taken along the line 16-16 of FIG. 15 and inthe direction generally indicated.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIGS. 1 and 2, a rod hanger suitable for incorporatingthe present invention is generally designated 10 and is shown securing athreaded rod 12 to a substrate 14. Included on a rod receiving portion16 configured for receiving the rod 12, are a top surface 18, a bottomsurface 20, and a hole 22 configured for threadaby engaging the rod 12.The hole 22 preferably includes a lip formation 24 disposed at leastpartially about the hole and is also configured to threadably engage therod 12.

A connecting element 26 is configured for vertically displacing amounting portion 28 and the rod receiving portion 16. In one embodiment,the planes respectively defined by the mounting portion 28 and the rodreceiving portion 16 are generally parallel. Preferably, the angles aformed by the connecting element 26 and the mounting portion 28 and bythe connecting element 26 and the rod receiving portion 16 will beapproximately ninety degrees. Other angular orientations arecontemplated for the angles a. Regardless of the specific angularorientation of the connecting element 26 relative to the mounting androd receiving portions 28, 16, the mounting portion should be disposedin a relatively flush relationship to the substrate 14 (best seen inFIG. 1).

It is also contemplated that the connecting element 26 further includesat least one and preferably two coined impressions 30 at a juncture 32defined by the connecting element 26 and the rod receiving portion 16,and at least one and preferably two coined impressions 30 at a juncture32 defined by the connecting element 26 and the mounting portion 28. Thecoined impressions 30 at the junctures 32 of the rod hanger 10 increasethe strength of the rod hanger. Further, the number and disposition ofthe coined impressions 30 may vary to suit the application. In addition,in the preferred embodiment, the mounting portion 28 and the rodreceiving portion 16 define a generally planar shape, and with theconnecting element 26 define a unitary body with a generally uniformthickness.

The mounting portion 28 includes a top surface 34, a bottom surface 36and a hole 38 configured for engaging a fastener 40. In the preferredembodiment, the top surface 34 of the mounting portion 28 includes atleast one, preferably several, anti-rotation elements 42 configured forengaging the substrate 14 and counteracting any rotational moments actedupon the rod hanger 10 after engagement with the substrate 14. It iscontemplated that at least one anti-rotation element 42 engages thesubstrate 14 along with a pin end 43 of the fastener 40. As such, theelements 42 need not be mounted on the top surface 34, but mayalternately be located elsewhere on the mounting portion 28, such as onedges or bottom surface 36.

Referring now to FIG. 2, the rod hanger 10, or any of the alternateembodiments described below is preferably provided with the fastener 40associated with the mounting portion 28 and is dimensioned to extendthrough the hole 38 in the mounting portion 28. This arrangementfacilitates one-handed application of the rod hanger 10 to the substrate14. The fastener 40 includes the pin end 43 connected to a shank portion44 and a head 45. Also included on the fastener 40 is an annular flutedmember 46 and a sleeve-like guard member 47 having a radially flared end48. The fluted member 46, typically made of plastic, circumscribes thefastener and facilitates the passage of the fastener in a powderactuated tool. The guard member 47 circumscribes the pin end 43 andtypically prevents injury prior to installation of the rod hanger 10.Upon driving of the fastener 40 into the substrate 14, the fluted member46 becomes crushed against the mounting portion 28, forming a resilientseal. Also, the guard member 47 becomes crushed between the mountingportion 28 and the head 45 (FIG. 1). The flared end 48 also becomescrushed between the substrate 14 and the mounting portion 28.

It is also contemplated that the anti-rotation elements 42 can have avariety of different forms and can be disposed in a plurality oflocations on the mounting portion 28. In addition, differentanti-rotation element shapes or different anti-rotation spatialconfigurations may be more suitable for different types of substrates.Some exemplary variations are depicted in FIGS. 3-17. In all of theembodiments depicted, common structural components have been designatedwith the same reference numbers.

Referring now to FIGS. 3 and 4, in the rod hanger generally designated10 a, the anti-rotation elements 42 are provided with a resilient rubberor polymeric cover 54 for enhancing the adhesion of the mounting portion28 to the substrate 14. It is contemplated that the cover 54 is securedto the elements 42 by overmolding, thermoforming, chemical adhesive orother known technologies, and that a lower margin 56 of the cover mayextend fully or partially over the element.

Referring now to FIGS. 5 and 6, the main distinction between the rodhanger 10 and the depicted alternate embodiment 58 is that theanti-rotation elements 60 have the shape of a truncated cone. In thepreferred version of this embodiment, the elements 60 are hollow. Upperedges 61 of the elements 60 are either straight or jagged.

Referring now to FIGS. 7 and 8, another alternate embodiment, generallydesignated 62 features the anti-rotation elements 64 provided in theshape of elongate bars. Two such bars 64 are preferably provided and aredisposed on either side of the hole 38; however, the number anddisposition of the bars may vary to suit the application. Also, it iscontemplated that the length of the bars 64 may vary, and, while showngenerally parallel to each other, the relative position of the bars mayalso vary. A top surface 66 of at least one bar 64 is generallyflattened or slightly hemispherical. When viewed from above, the atleast one anti-rotation element 64 has a generally rectangular shapewith a contoured surface.

Referring now to FIGS. 9 and 10, another alternate embodiment, generallydesignated 68, features a plurality of generally pointed anti-rotationelements 70. In the preferred embodiment, the elements 70 have atriangular base 72 and three facets 74. However, the precise shape ofthe base 72 and the number of facets 74 may vary to suit theapplication. An advantage of the pointed shape of the elements 70 isthat the mounting portion 28 is more securely retained than if generallyhemispherical elements are provided. While four, generally equallyspaced elements 70 are depicted disposed about the hole 38, the numberand disposition of the elements may vary to suit the application.

Referring now to FIGS. 11 and 12, another alternate embodiment isgenerally referred to as 76, and features anti-rotation elements 78configured as elongate, upturned edges of the mounting portion 28. Theelements 78 preferably extend the full length of the mounting portion28, but their length may vary to suit the application. Also, upper edges80 of the elements 78 are generally flattened, but other shapes, such asrounded, are also contemplated. While opposing edges of the mountingportion 28 are shown upturned, it is also contemplated that a free edge82 can alternately be upturned. In the preferred version of thisembodiment, the elements 78 are upturned at generally right angles tothe mounting portion 28. Other angular orientations are contemplated.

Referring now to FIGS. 13 and 14, yet another alternate embodiment isgenerally designated 84 and features anti-rotation elements 86 which areformed by upturned edge regions of the mounting portion 28. The elements86 are formed by stamping and bending the desired areas of the mountingportion 28. In the preferred version of this embodiment, there are fourupturned elements 86 disposed uniformly about the hole 38; however, thenumber and orientation of the elements may vary to suit the application.Also, top surfaces 88 are preferably generally flattened, and theelements 86 preferably form right angles relative to a plane defined bythe mounting portion 28. The angular orientation of the elements 86 mayalso vary to suit the application. Also, the length of the elements 86may vary provided there is at least some gap between adjacent elements.

Referring now to FIGS. 15 and 16 still another alternate embodiment isgenerally designated 90 and features anti-rotation elements 92 which aresimilar to the elements 86 but are pointed at tips 94. The elements 92are upturned towards each other along a common edge of the mountingportion 28. While four elements 92 are depicted and are disposeduniformly about the hole 38, the number and orientation of the elementsmay vary to suit the application. Also, the optimal angular orientationof the elements 92 relative to a plane of the mounting portion 28 isninety degrees. However, other angular orientations are contemplated,provided that the elements 92 provide anti-rotation gripping actionagainst the substrate 14.

Thus, it will be seen that the present rod hanger 10, as well as thealternate embodiments 58, 62, 68, 76, 84 and 90 all feature at least oneanti-rotation element for facilitating the attachment of the hanger tothe substrate 14. Depending on the composition of the substrate 14, theanti-rotation elements may be provided in a variety of shapes anddispositions. It is also contemplated that further alternate embodimentsmay be provided incorporating combinations of any of the shapesdescribed above. For example, such a combination can include elements60, 64 and 70; however other combinations of the elements describedabove may be provided. Additional structural support is preferablyprovided by the coined impressions 30.

While particular embodiments of the present rod hanger for securing arod to a substrate have been described herein, it will be appreciated bythose skilled in the art that changes and modifications may be madethereto without departing from the invention in its broader aspects andas set forth in the following claims.

1. A rod hanger for securing a rod to a substrate, comprising: amounting portion configured for engaging the substrate; a rod receivingportion configured for receiving the rod; a connecting elementconfigured for vertically displacing said mounting portion and said rodreceiving portion; and at least one anti-rotation element on saidmounting portion configured for engaging the substrate.
 2. The rodhanger of claim 1, wherein at least one of said mounting portion andsaid rod receiving portion define a generally planar shape.
 3. The rodhanger of claim 1, wherein said mounting portion includes a top surface,a bottom surface and a hole configured for engaging a fastener.
 4. Therod hanger of claim 3, wherein said top surface of said mounting portionincludes at least one said anti-rotation element.
 5. The rod hanger ofclaim 1, further including a fastener associated with said mountingportion and dimensioned to extend through a hole in said mountingportion.
 6. The rod hanger of claim 5, wherein said fastener includes apin end connected to a shank portion and a head.
 7. The rod hanger ofclaim 6, wherein said fastener further includes a fluted member and aguard member.
 8. The rod hanger of claim 1, wherein said rod receivingportion includes a top surface, a bottom surface and a hole configuredfor threadably engaging the rod.
 9. The rod hanger of claim 8, whereinsaid hole includes a lip formation disposed about said hole andconfigured to threadably engage the rod.
 10. The rod hanger of claim 1,wherein planes respectively defined by said mounting portion and saidrod receiving portion are generally parallel.
 11. The rod hanger ofclaim 1, wherein said connecting element includes at least one coinedimpression at a juncture defined by said connecting element and said rodreceiving portion and at least one coined impression at a juncturedefined by said connecting element and said mounting portion.
 12. Therod hanger of claim 1, wherein said rod hanger defines a unitary bodywith a generally uniform thickness.
 13. A rod hanger for securing a rodto a substrate, comprising: a mounting portion configured for engagingthe substrate; a rod receiving portion configured for receiving the rod;a connecting element configured for vertically displacing said mountingportion and said rod receiving portion; and at least one anti-rotationelement on said mounting portion configured for engaging the substrate,wherein the anti-rotation element is disposed on the mounting portion toengage the substrate and counteract a moment acting upon said rod hangerafter said rod hanger has been engaged with the substrate.
 14. The rodhanger of claim 13, wherein said at least one anti-rotation element hasa generally hemisphered shape.
 15. The rod hanger of claim 13, whereinsaid at least one anti-rotation element is provided in a generallytruncated hollow cone shape.
 16. The rod hanger of claim 13, whereinsaid at least one anti-rotation element is configured in a generallyrectangular shape with a contoured surface.
 17. The rod hanger of claim13, wherein said at least one anti-rotation element has a generallypointed shape.
 18. The rod hanger of claim 13, wherein said at least oneanti-rotation element is configured in a generally rectangular shape andforms a raised edge at corners of the mounting portion.
 19. The rodhanger of claim 13, wherein said at least one anti-rotation element isformed from an upturned edge of said mounting portion.
 20. The rodhanger of claim 13, wherein said at least one anti-rotation element isconfigured in a generally rectangular shape and is formed from anupturned edge at at least one corner of said mounting portion.
 21. Therod hanger of claim 20 wherein top surfaces of said at least oneupturned edge are one of flat and pointed.
 22. The rod hanger of claim13, wherein said mounting portion includes a top surface, a bottomsurface and a hole for engaging a fastener, and said anti-rotationelement is disposed on said top surface of said mounting portion toengage the substrate.